Note: Descriptions are shown in the official language in which they were submitted.
1~3~ S
The present invention relates to a multi-component
composite filament. Binary composite filaments are well known.
The most representative kind of these filaments is made by removing
one component from two components or separating one component from
the other to form a bundle of superfine filaments.
However, the so obtained bundle of superfine filaments
and fabrics made from such filaments frequently has the following
drawbacks:
(1) Because they are superfine filaments, they are
extremely low in rigidity and lacking in bulkiness. This result
occurs in both of the aforementioned methods of manufacture.
(2) Napped fabrics, for example, velvet-like knitted or
woven fabrics, raised fabrics, buffed fabrics of non-woven velveteen,
corduroy, seal, fur and electrodeposited fabrics have been commonly
lacking in natural tone and high quality feeling. In other words,
they have been excessively uniform and monotonous.
(3) It has been difficult to produce fabric having a
crisp feel, with crepe, tenseness, and stretch recovery having
little tendency for individual threads to be loosened, further
having variety in color tone, and resembling silk.
(4) In the case of a bundle of superfine filaments which
is 100~ composed of composite filaments, the characteristics of the
bundle are frequently less beneficial than might be expected based
on the crimp capacity of the fil~aments. On the other hand, in
accordance with the present invention, there has now been developed
a three or more component composite filament, from which one
component may be removed, thus producing a composite filament
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consisting of the other two components. Furthermore, a fabric
having a peculiar feel may be made from the new filament.
The novel composite filament drastically is improved with
respect to the aforementioned drawbacks. In addition, this novel
composite filament may have various other novel characteristics
which have not been seen in prior composite filaments.
According to the present invention, there is provided a
multi-component composite filament having an "islands-in-sea" type
cross-sectional configuration and convertible into a bundle of
superfine filaments, said composite filament comprising
(A) at least two different kinds of filamentary islands
having different contracting or crimping properties each dispersed
- independently in said sea without maldistribution of such filamen-
tary islands to any one side of said sea as viewed in said cross-
sectional configuration, said composite filament being further
characterized by (1) the respective kinds of filamentary islands
having different coefficients of free contraction of at least 5%,
or (2) one of said filamentary islands comprising a one component
filamentary type and the other of said filamentary islands
comprising (a) a bicomponent filamentary type in which a plurality
of different polymers are adhered together or (b) an eccentrically
shaped filamentary type having at least two components, the sum of
the weights of said filamentary islands being greater than the
weight of said sea, said filamentary islands being convertible,
upon separation from said sea and upon differential contraction,
into a bundle of puffy superfine filaments, or
(B) filamentary islands and a sea having different
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contracting or crimping properties, the filamentary islands
dispersed independently in the sea without maldistribution of
such filamentary islands to any one side of said sea as viewed in
said cross-sectional configuration, said composite filament being
further characterized by (1) the filamentary islands and the sea
having different coefficients of free contraction of at least 5%,
or (2) the filamentary islands being a member selected from the
group consisting of a bicomponent filamentary type in which a
plurality of different polymers are adhered together and an
eccentrically shaped filamentary type having at least two components,
and the sea being a member selected from the group consisting of a
one component filamentary type and a multicomponent filamentary type
having one major component, with the proviso that said filamentary
islands are of a different filamentary type from said sea, said
filamentary islands and said sea being convertible, upon separation
from each other and upon differential contraction, into a bundle of
puffy superfine filaments.
In another aspect of the present invention, there is
provided a method of forming a fabric from the multi-component
61!~'nc~ 0.~9~C
composite filament o'f claim 1, said fabric being composed of an
aggregation of a plurality of bundles of superfine filaments, said
method comprising taking a plurality of said composite filaments
and forming a sheet-like fabric, separating said filamentary islands
from said sea and then differentially contracting the filamentary
islands or the filamentary islands and the sea to form said bundles
of superfine filaments in which each type of superfine filament is
dispersed wichout maldistribution in a said bundle.
In yet a further aspect, the invention provides a fabric
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composed of an aggregation of a plurality of bundles of superfine
filaments, each such bundle being obtained by separating said
superfine filaments from a multi-component composite filament, each
such bundle comprising at least two different types of superfine
filaments which have different coefficients of free contraction,
each type of superfine filament being dispersed without maldistri-
bution in said bundle, and wherein either (a) one of said superfine
filaments is a member selected from the group consisting of a one
component filamentary type and a multi-component filamentary type
having one major component and the other superfine filament comprises
(1) a bicomponent filamentary type in which a plurality of different
polymers are adhered together or (2) an eccentrically shaped fila-
mentary type having at least two components, or (b) one of said
superfine filaments is a member selected from the group consisting
of a one component filamentary type, a bicomponent filamentary type
in which a plurality of different polymers are adhered together, and
an eccentrically shaped filamentary type having at least two
components and the other of said superfine filaments is a member
selected from the group consisting of a one component filamentary
type and a multi-component filamentary type having one major
component, with the proviso that said superfine filaments and
said other superfine filaments are of different filamentary types.
Thus two particular types of multi-component composite
filament of the present invention may be stated as follows:
(1) A multi-component composite filament having an
"islands-in-sea" type cross-sectional configuration in which at
least two different kinds of filamentary islands are dispersed
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independently without maldistribution to one side in a sea component
(i.e., the different filamentary islands are not unevenly distri-
buted such that the weight of any one component predominates on
any one side of the composite filament), wherein the respective
filamentary islands have different coefficients of free contraction
of at least 5%, and wherein the sum of the weights of these
filamentary islands exceeds the weight of the sea.
(2) A multi-component composite filament having an
"islands-in-sea" type cross-sectional configuration in which at
least two different kinds of filamentary islands are dispersed
independently without maldistribution of any one component to one
side in a sea component, wherein one individual kind of filamentary
island consists of an island of the usual type and the other
individual kind of filamentary island comprises a binary bi-
component-type or eccentric-type composite superfine filament, and
wherein the sum of the weights of these filamentary islands exceeds
the weight of the sea.
Particular embodiments will now be described in detail
with reference to the acoompanying drawings, in which:
Figure 1 is a schematic view showing a bundle of super-
fine filaments obtained from a conventional composite filament.
Figures 2a and b are explanatory views showing the
principle by which superfine filaments become bulky.
Figures 3 - 36 are cross-sectional views of various
embodiments of composite filaments according to the present
invention.
Figure 37 is a schematic view showing overlap of crimps
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1~31~1~i5
(at the time of free crimping) of a bundle of conventional super-
fine filaments.
Figure 38 is a schematic view showing bulkiness and
peculiarity of a bundle of superfine filaments (at the time of
free crimping) according to the present invention.
Figure 1 is a schematic view of a bundle of superfine
filaments, illustrative of the present invention, as well as a
conventional bundle of superfine filaments. Selected filaments of
such a bundle, enlarged, are also shown in Figure 2(a). However,
when this bundle is subjected to contraction, in accordance with
the present invention, it appears as shown in Figure 2(b), wherein
a superfine filament is contracted and is crimped, while other
superfine filaments which are less contracted are properly inter-
posed among the contracted superfine filaments and the resulting
superfine filament bundle becomes puffy. Accordingly, when
filamentary islands of components A or B are maldistributed in sea
C and A and B are not mixed at least somewhat symmetrically, there
is little uniformity of puffiness. This is not preferred. It is
preferable that these filamentary islands of components A or B
should be well mixed and mutually interposed. In this sense, it
is important that the multi-component composite filament of the
present invention be convertible to a bundle of puffy superfine
filaments.
The composite filament according to the present invention
is convertible to a superfine multifilament bundle, wherein crimped
or slack superfine filaments and straight superfine filaments co-
exist without maldistribution, by dividing and contracting
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treatments to be described in detail hereinafter. The superfine
filament bundles of the present invention may be roughly divided
into three types.
A first type has at least two different kinds of
filamentary islands of components A or B, both A and B being
independently dispersed in a sea C of another component.
Filamentary islands of components A or B may have various types of
cross-sectional areas, examples of which are shown in Figures 3 - 10.
Filamentary islands of components A or B in Figure 3 are
shown to be dispersed in a regularly interposed pattern in sea C.
When the deniers of these islands are within the range of 2 - 0.6 d,
this composite filament is very useful as a material for producing
silk-like and wool-like fabrics in a manner to be described in
detail hereinafter. This composite filament is also effective as
a starting material for making plush, velveteen and corduroy.
Figure 4 is an example wherein two filamentary islands of
components A or B are in a regularly dispersed but random mixed
arrangement. The islands of components A and B are mutually, but
randomly interposed.
In Fi-gure 5, filamentary islands of components A or B are
disposed in a manner similar to the filamentary islands in Figure 3.
However, a composite filament of this type may be called a peeling
type o~ an exposed surface type because the other surfaces of the
islands are exposed. When the islands are separated and become
independent, the sea C remains as a fiber, requiring separate
consideration.
Figure 6 shows an example wherein one of the filamentary
t
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islands of components A or B, the inner grouping of islands of
component A in the example illustrated, is surrounded by the outer
grouping of the other island of component B. In this case, too,
one island is interposed with respect to the other.
Figure 7 shows another example in which the grouping of
filamentary islands of component A extends through the grouping of
islands of component B.
Figure 8 is a peeling type composite filament, with both
types of filamentary islands having exposed surfaces. In this
case, after mechanically peeling the islands of components A or B
from the sea C, it is possible to further halve the islands.
Figure 9 is a hollow type composite filament wherein four
islands of component A and four islands of component s are provided
and wherein it is possible to peel away the interposing sea C, or
otherwise to remove the sea C.
Figure 10 is an example of another form of composite
filament wherein filamentary islands of components A or B are
regularly but differently disposed. In this example, a denier mix
is accompanied by a mixing of heterogeneous cross sections. When
a wool-like composite filament is to be made, a filament of the
type shown in Figure 10 is especially preferable as a starting
material. In this case, a multi-lobal cross section (at least
trilobal) is especially preferable.
In the cases illustrated in Figures 3 - 10, it is
necessary that there be a difference in coefficient of contraction
between the two filamentary islands of components A and B
respectively. That difference should be at least 3~, but
1~381~S
preferably is at least 5%. This is especially true in the case of
filaments in which the sea C is peeled away but is allowed to
remain in the admixture with the filamentary islands. The
difference in coefficient of contraction as referred to herein,
means a difference in the coefficient of free contraction without
hinderance. Ordinarily, the coefficient of contraction of a
filament in a knitted or woven fabric is often lower than its
unhindered coefficient of free contraction due to restrictions in
the fabric. Even though the difference of the respective
coefficients is small, it still greatly affects fabric bulkiness.
Accordingly, the respective coefficients of contraction are
measured after separating or peeling the filamentary islands of
components A and B from the sea C by use of a solvent or decompo-
sition agent which has the least effect upon the filamentary islands
of components A and B. Contraction may be measured by any one of a
variety of procedures including boiling water contraction, solvent
contraction and high-temperature heating contraction. As stated,
the difference of coefficient of contraction should be at least 3%
when tested by any one of these contraction test methods. Typically,
the boiling water contraction method and the high-temperature dry
contraction method are commonly used. In this specification, the
contraction values referred to are often based on these test methods.
Thus, a filamentary type whose coefficient of contraction
is small slackens relative to a filamentary type whose coefficient
of contraction is large, thus making a bulky and puffy bundle of
superfine filaments.
This puffiness may be brought about with the filament in
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1131~1~S
the form of a yarn, but it is more effective with the filament in
the form of a fabric.
The relation between disposition of filamentary islands
components A and B in the cross-sectional area of a composite
filament and the difference in coefficient of contraction is
important.
A second type of composite filament in accordance with
the present invention is shown in Figures 11 - 26, in which
filamentary islands of components A or s are separated by sea C.
In this type of composite filament, the filamentary islands may be
a mixture of components A and s having a bicomponent-type or
eccentric-type cross-sectional configuration, which are intended
to be removed and separated from sea C. Also, the resultant bundle
of superfine filaments may consist of a single component filamentary
type of the component A or B in admixture with filamentary types of
the remaining components of the original composite filament. For
instance, in the case of Figure ll, there is shown a bicomponent-
type composite superfine filament (a filamentary island) consisting
of two adhering components A and B, and a superfine filament (the
sea) of one component in admixture therewith arranged in the shape
of a cross. In the case of, for example, Figure 13, the composite
filament comprises a bundle of superfine filaments consisting of a
bicomponent-type composite superfine filament consisting of adhering
components A and B in combination with a cross-shaped superfine
filament of sea C, as well as other superfine filaments consisting
of the component A alone and the component B alone. When considered
similarly, it may be easily understood what sorts of bundles of
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superfine filaments are shown in each of the other figures.
Namely, throughout all the examples of Figures 11 - 26, combinations
are shown each consisting of a bicomponent filamentary type or
eccentric filamentary type composite superfine filament and super-
fine filaments consisting of substantially a single component.
A third type of composite filament of the present
invention is that in which, after sea C has been dissolved and
removed, there remains a bundle of superfine filaments consisting
of a combination of bicomponent filamentary types or eccentric
filamentary types each consisting of components A and B, combined
with superfine filaments of a single component type consisting of
the components A or B or both. This combination of (a) bicomponent
or eccentric and (b) single component superfine filaments is shown
for example, in Figures 13, 16, 18, 20, 21, 22, 23 and 27 - 36.
Figures 27 - 36 particularly show examples of composite filaments in
each of which the filamentary islands of components A and/or B are
surrounded by sea C.
In each of these second and third types of filaments of
the present invention utilizing bicomponent filamentary types,
components A and B that are adherent to each other, yet have
different coefficients of contr~action, are selected as the
filamentary islands. Only when these conditions are met are very
excellent effects, to be mentioned later, obtained. When all of the
filamentary islands are composite, having roughly the same coefficient
of contraction and the sea is removed, only crimp will be produced
by heat and solvents as shown in Figure 37. In such crimping, loops
of crimp often overlap and the feel of the resulting bundle or
fabric is different than bundles or fabrics of this invention and
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it is difficult to produce enough bulkiness in many cases.
sy contrast, in the use of the present invention, with
the differential coefficients of contraction, as shown in Figure 38,
a superfine crimped filament overlaps with another superfine
straight filament, which is exactly the same result illustrated
in Figure 2b. This is true, (even if each crimp does not make a
complete loop, though the effect of the crimp in that case may be
less).
In accordance with the present invention, compared with
filaments where all reveal crimp, a very peculiar filament is
produced having a voluminous feel, which is unexpected. This may
be used to bloom naps of raised fabrics. Accordingly, compared
with the crimp produced in a bundle of crimped superfine filaments
as shown in Figure 37, which has heretofore been considered most
excellent, a bundle of crimped superfine filaments of a superior
structure may be obtained according to the present invention. In
addition, such filaments may have no crimp while being processed
into a woven fabric, knitted fabric or non-woven fabric, and are
less bulky and easy to process. After a sheet-like fabric has been
formed, said filaments may be rendered superfine by mechanical or
chemical actions and said superfine filaments may be treated to
produce crimp by further heat-treatment or chemical treatment.
Accordingly, in regard to the present invention, it should be noted
that it is not necessary that a bundle or mixture consisting of
crimpable superfine filaments and non-crimpable superfine filaments
or contractable superfine filaments and non-contractible superfine
filaments be made first, and then that such bundle or mixture be
processed into filaments. Rather, superfine filaments having such
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potential are readily processed in a fasciated state, namely, in aneasily processable condition like the filaments of an ordinary yarn.
Thereafter the respective superfine filaments are separated and made
independent from such fasciated component, to produce particular
effects of this invention.
As mentioned above, composite filaments used in the
present invention are roughly divided into three types, the
characteristics of each of which will be mentioned hereinafter.
In the first type, namely, in the case of each of the
composite filaments shown in Figures 3 - 10, the contraction force
is relatively strong, even in a restrained state, for example. As
formed into a fabric, the product may become comparatively bulky.
In other words, with regard to the difference in
coefficient of contraction of the superfine filaments, the loss of
crimpability due to making the composite filament superfine is
small. In addition, compared to ordinary filaments, such as super-
fine multifilaments, according to the present invention, are mixed
without being maldistributed. There is good affinity between the
different superfine filaments, and the bundle of different super-
fine filaments shows a good tendency to become puffy.
In the second type, namely, in composite filaments suchas those shown in Figures 11 - 26; a mechanical peeling method is
applied and the chemical aid of a solvent is not necessary; accord-
ingly there is no reduction of contractibility due to the action
of the solvent; therefore, when a method of thermal contraction is
adopted between two components A and B, crimp is very likely to be
brought about. However, in this type of composite filament, peeling
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has to be carried out mechanically, and even when component C is
unnecessary, for example, from the point of view of dyeing fastness,
it may nevertheless be allowed to remain present. However, such
composite filaments may peel at a stage when peeling is not wanted
and this may be a drawback in that such a filament may have
comparatively poor processability. On the other hand, there is,
of course, no loss of components. These points become merits or
demerits, depending upon the object at hand.
In the third type of composite filament in accordance with
the present invention, as illustrated by Figures 27-36 of the draw-
ings removal of one component is normally carried out by dissolution.
Owing to the use of a chemical solvent, crimpability due to difference
of contraction between the two components A and B is often inferior.
The contraction power of one component is reduced by a crystalli-
zation phenomenon caused by the solvent of sea C, which is called
solvent crystallization. When heating is effected at the time of
dissolution, loss of crimpability is even more likely. There are
also other necessary drawbacks in removing one component by
dissolution, including the loss of the component in solution.
; 20 However, as an advantage, the removal of the dissolved component
creates spaces providing room among the superfine filaments, which
contributes to a considerable feel-improving effect, which cannot
be overlooked. In other words, this type of filament and procedure
also has its merits and demerits.
Composite filaments of the third type having an "islands-
in-sea" type cross-sectional configuration, as shown in Figures 27 -
36, are especialiy important because in an "islands-in-sea" type
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filament, filaments are well fasciated. Such a filament has good
processability because of the high degree of filament concentration
in the non-bulked state. This cannot be overlooked. It is another
characteristic that a treatment which forms spaces among filaments
by removal of component C brings about an effect similar to that of
removing sericin from silk consisting of sericin and fibroin by
degumming. It is still another characteristic of composite filaments
of the third type that it is possible to select components of the
same kind such as, for example, polyesters having different contract-
ibility and to make it possible to mix different kinds of components,such as a polyamide and polyethylene.
In the foregoing description; the merits and demerits of
the respective embodiments of this invention have been mentioned so
that different forms of the invention may be properly used in
accordance with the user's intended objects. What may be said about
them in common is that, as shown in Figure 38, a bundle is so made
that a superfine filament (or a plurality of such superfine
filaments) treatable to form a superfine crimp is interposed among
other superfine filaments which, under the same treatment, do not
form a superfine crimp. Therefore, effects in bulkiness, mutual
dispersion among filaments and improvement in feel are brought about,
depending on the selection of filamentary type and composition.
These composite filaments may be used for production of
various kinds of fiber products such as woven fabrics, knitted
fabrics and non-woven fabrics. Examples of woven fabrics include
crepe, such as crepe de Chine, palace crepe, satin crepe, morocain
crepe, striped crepe, oriental crepe, flat crepe, georgette crepe
1~3~1~;S
and silk crepe, or various kinds of crepe weaves, such as amundsen
jersey. Other examples include habutae (glossy) silk, satins, silk
gauzes, voiles, porous fabrics, twill weave, serges, taffetas,
cord weaves, velvets, towel weaves, flannels, shirting and various
other designs of weave. Above all, these composite filaments are
preferably used for producing raised fabrics such as velvet,
velveteen and corduroy and further fabrics of a type which is
raised by use of a raising machine.
As to knitted fabrics, besides various conventional
knitted fabrics, other knits, such as platen or tricot fabrics or
two-ply fabrics, of which especially those which are raised or
napped may be cited, may also be made from filaments of the present
invention.
Among-non-woven fabrics, one should include needle
punched non-woven fabrics, non-woven fabrics made by the paper
making types of methods, and also spun bond non-woven fabrics.
From such woven, knitted or non-woven fabrics it is possible to
make raised fabrics having good nap dispersibility by subjecting
them to napping and/or buffing. It is also possible to make a
raised fabric such as velveteen or velvet by cutting to make them
into piled fabrics. In each of these instances, the suprisingly
advantageous effects of the present invention are effectively
revealed.
It is especially preferable that the deniers of filaments
after being made superfine should be about 0.05-0.6 in the case of
raised fabrics and about 0.6-2.0 in the case of non-raised fabrics.
It is preferaole that the denier of the composite filament before
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being made superfine should be within the range of about 15-1
denier. In the case of mixed denier, it is preferable that the
difference of deviation of the various deniers of the filaments
after being made superfine should not exceed about 1.0 denier.
AS regards treating the filaments for the purpose of imparting
crimp thereto, heating is especially preferable.
The most preferable combination of the component A and B
is a combination of po1yesters, particularly a combination of poly-
ethylene terephthalate with the product obtained by copolymerizing
isophthalic acid or sodium sulfonate isophthalate with the same,
with the products obtained by copolymerizing a small amount of a
trifunctional component with the same, or with polybutylene
terephthalate or other known polyesters with the same.
The amounts, components and draw conditions are so
determined as to bring about a difference in coefficient of
contraction. Also, various polyamides, namely, nylon 6, nylon 66,
PACM-, IPA- and TPA- copolymerized nylon 66 and various other
copolymers are preferable as the components A and B. It is a matter
of course that combinations of polymers of different series are
acceptable.
As the component C, there may be cited polymers of the
polystyrene series, polymers of the polyvinyl series, copolyesters,
polymers of the polyamide series and polymers of the polyolefin
series. The component C may be properly used by dissolving and
removing the same or by peeling the same.
It goes without saying that for use as the components A,
B and C, all the known fabric-forming polymers are applicable as
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well as those mentioned above.
When the remaining component is polyester, it is
especially preferable for producing a silky, feel to treat poly-
ester with an alkali solution. An original yarn may be also
textured-processed, such as by false weave processing and made
into a yarn having strong twist. For example, a combination with
strong twist SZ is possible.
It is a matter of course that when the two components A
and B are different in dyeability, it is possible to dye them
differently, and it is possible to subject them to resin processing
and to process them by adding a feel-improving agent such as poly-
urethane and silicone. When, for example, such filaments are
needle punched, processed with polyurethane before the component
C is removed and thereafter buffed, it is possible to make a fabric
consisting of said filaments into suede-like artificial leather and
to produce a product having excellent feel by so doing.
_ample
A three-component "islands-in-sea" type composite
filament having a cross sectional area as shown in Figure 4 was
produced by using polyethylene terephthalate to form a filamentary
island of one component and, as another filamentary island, a
copolyethylene terephthalate containing 9.9 mol ~ of an isophthalic
acid component. Specifically, by using a spinneret (for 42
filaments) for a composite filament which consisted of a number of
cores embedded in the matrix, said cores being extremely fine and
parallel to each other along the fiber axis as shown in Japanese
Patent Application Publication No. 26723/1972, the aforementioned
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composite filament was first spun in the usual way at 280C, then
wound, and finally drawn with heating to obtain a 3.8 denier yarn.
The number of filamentary islands so obtained was equal to sixteen,
eight of which consisted of polyethylene terephthalate and eight of
which consisted of copolyethylene terephthalate; all such filament-
ary islands accounted for 60% of the yarn.
This filamentary yarn was washed well with carbon tetra-
chloride and dried to obtain a bundle of superfine filaments. At
this point the bundle thus obtained was free from swelling; however,
when the bundle was immersed in boiling water, filaments consisting
of said copolyester having copolymerized isophthalic acid contracted
greatly. As a result, a remarkable swelling was seen in the bundle
of superfine filaments. The difference in coefficient of contract-
ion between the highly contractable component and the slightly
contractible component was not less than 5%. It is notable that
the component having the higher coefficient of contraction appeared
to have been drawn to the inside of the fiber.
Example 2
A drawn composite filament having a cross sectional area
as shown in Figure 3 was produced, wherein the two kinds of the
filamentary islands were the same as in Example 1, but the sea
component thereof was polystyrene which had 22% by weight of co-
polymerized 2-ethylhexyl acrylate, the island/sea ratio being
85/15.
Using a yarn consisting of such composite filament both
as warp and weft, the following plain fabric was woven. Specifi-
cally, in weaving the plain fabric for the warp, a total 50 denier
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of about 5.6 d/9 fil yarn was used, at a plain fabric density of
110 warps/in; for the weft, a total 73 denier of about 5.6 d/13
fil yarn was used at a plain fabric density of 83 wefts/in. Two
such woven fabrics were prepared; one fabric was washed with carbon
tetrachloride while the other fabric was washed with trichloro-
ethylene. Each was dried and then immersed in boiling water. Both
such treatments cause fabric swelling, but the swelling of the
fabric washed with the carbon tetrachloride was superior to the
swelling of the fabric washed with trichloroethylene. Said fabric
was subsequently washed in a hot 2.5 g/liter aqueous bath of
sodium hydroxide, the surface thereof finally treated with an
alkali, washed with water, dried and finally passed through air at
180C for a short period of time. The product thus obtained was a
pli~nt woven fabric having a silk-like luster and feel.
Example 3
A composite filament was produced which consisted of many
cores embedded within the matrix, said cores being extremely fine
parallel to each other along the fiber axis. The composite filament
further had an "islands-in-sea" type cross sectional configuration
with thirty six islands, of which half were polyethylene tere-
phthalate and half were copolyethylene terephthalate containing
9.9 mol ~ of an isophthalic acid component as in Example l; the
- sea component was polystyrene, and island/sea ratio was 95/5. The
thus obtained drawn yarn consisting of total denier 100 d/25
filaments was used as the pile yarn when weaving velvet-like fabrics.
As both warp and weft of the base texture, a 50 D - 36 f bulky
processed yarn having a T-shaped cross sectional configuration
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~"~
-
1~3~
(process for producing the same being disclosed in Japanese Patent
Application Publications Nos. 18535/1976 and 47550/1972) was used
and the length of the raising was made to equal 1.0 mm. Two such
fabrics were prepared, each of which was washed with a sufficient
amount of an alkali; then with a sufficient amount of water.
Thereafter, one fabric was washed with carbon tetrachloride and the
other fabric was washed with trichloroethylene. It is necessary to
sufficiently wash the fabric with water after the alkali treatment,
but prior to the trichloroethylene washing in order to prevent the
production of explosive dichloroacetylene.
Next, when the two fabrics were exposed in hot air at
180C and thereafter dyed in blue, very elegant raised fabrics
(which might be well called velvets having suede effects) having
different pile ~raising) lengths were obtained.
Example 4
A three-component composite filament having an "islands-
in-sea" type cross sectional configuration as shown in Figure 27
(number of islands: 4) was made. Namely, as component A, poly-
ethylene terephthalate was used, and as component B, copolyethylene
terephthalate having copolymerized 10 mol % of isophthalic acid was
used. The ratio of A/B was made 75/25. As component C, polystyrene
was used. The ratio of component C to the entirety was made 20%.
;~ The composite filament having a cross sectional configuration was
spun by a three-component filament spinning machine and drawn to
3.3 times. The obtained yarn was about 4 denier/12 fil. A skein
consisting of a plurality of such yarns was made and thereafter,
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165
the component C consisting of polystyrene was dissolved with carbon
tetrachloride and removed. Thereafter, when crimp was imparted by
the treatment of boiling water, the skein became very bulky. When
this skein was grabbed by hand, the bulkiness was high and a
remarkable difference was recognized compared with the following
comparative example.
Comparative Example
A composite filament having an "island-in-sea" type cross
sectional configuration similar to that of Figure 27 was produced,
wherein the entire island components were polyethylene terephthalate
only and the component C (sea component) was polystyrene. The
denier and island/sea ratio were so adjusted as to become the same
as in Example 1. Similarly, component C was dissolved with carbon
tetrachloride and removed and thereafter what was obtained was
treated in boiling water and dried.
On the other hand, using a composite filament whose cross
sectional configuration was similar to that of Figure 27, with the
exception that all the filamentary islands had an A/s component
filamentary type composite structure, a skein was made by the same
manner as in Example 4.
When the so obtained two samples were compared (after
drying) with the product of the present invention obtained in
Example 1, the product of the present invention was superior in
bulkiness. Bulkiness was measured by strongly grabbing the skein
many times by hand, and the state of each skein was checked after
the hand had been removed. The skein of composite filaments wherein
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.D'
1~31~t1&5
all the filamentary islands were the same was lowest in bulkiness,
followed by the skein of composite filaments wherein all filament-
ary islands comprised a bicomponent filamentary type. The product
of the present invention was the best in bulkiness properties.
This skein (present invention) comprised an aggregate of bundles of
superfine filaments having a different hand when compared to the
other two skeins.
Example 5
Using the same filament yarn as in Example 4, a plain
fabric was woven. Its density was 115 warps/in and 83 wefts/in.
This fabric was dissolved with carbon tetrachloride. Thereafter,
its surface was washed with hot alkali diluted with water, to
slightly dissolve the surface. Thus, it was washed with water and
dried. Crimp was imparted to an extent sufficient to separate one
superfine filament from another inside the organization. A silk-
like feel was evident on the fabric surface and said plain fabric
; exhibited very excellent, silk-like qualities.
Example 6
,~.
Example 5 was repeated except polybutylene terephthalate
was used instead of a copolyethylene terephthalate having
copolymerized isophthalic acid as component B. Also trichloro-
ethylene was used as a solvent in treating the plain fabric. The
resulting fabric was somewhat different in hand from the woven
fabric obtained in accordance with Example 5. The repulsion and
bulkiness of this fabric also differed from the fabric produced in
Example 5. However, this fabric also exhibited excellent woven
:: ;: , '
,
~3t~ iS
silk-like qualities.
Example 7
A composite filament having an "island-in-sea" type cross
sectional configuration of the type shown in Figure 29 was produced.
The total number of islands was sixteen and island component A
comprised a copolyester containing polyethylene terephthalate and
9.9 mol ~ of isophthalic acid. The island component B comprised
polyethylene terephthalate. The ratio was (A/B=12/4), and the sea
component was a styrene - octyl acrylate (78/22) copolymer present
in an amount equal to 4% of the entire composite filament. The
filament was spun as a composite filament consisting of many cores
embedded with the matrix. Said cores were extremely fine, drawn
and parallel to each other along the fiber axis. The total denier
and number of filaments in the yarn produced therefrom were 104 D -
42 f. Using the obtained yarn as the "nap" warp, a 50 D - 18 f
united filament (100 D) as texture warp and as texture weft, a
2-ply velvet weave was produced. The length of the raising (naps)
in the fabric was about 0.9 mm and the fabric density was 60 warps/
in and 90 wefts/in. This woven fabric was washed with trichloro-
ethylene in a washing machine and dried. Thereafter, said wovenfabric was treated in boiling water under relaxed conditions and
heat set at 170C for 5 minutes. Thereafter, it was dyed black
in a liquid stream circular dyeing machine at 120C under pressure.
The resulting fabric had naps which could be well bloomed and there
were intervals among the naps. Also, light fuzz was mixed in the
naps and the overall hand of the fabric was that of a very soft
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Dj~
1~3fl~5
raised woven fabric. On the other hand, a fabric produced according
to this example (with the exception of using a composite filament
whose islands all comprised component A) is obviously different in
appearance and luster compared to the fabric of this example.
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